Depositing heat-treated aluminum using ultrasonic consolidation

Abstract

A system, method, and articles are disclosed with respect to depositing aluminum or alloys thereof, utilizing ultrasonic object consolidation. The method aspect of the invention comprises the steps of heat-treating an aluminum-based feedstock and ultrasonically consolidating the feedstock to a substrate to produce a part or a repair of a part, as might be required in an aerospace or aircraft structure. The feedstock may be solution heat-treated. This would include situations wherein the feedstock is solution heat treated off-line and maintained under controlled temperature conditions to prevent precipitation of solutes prior to the ultrasonic consolidation. Alternatively, the feedstock may be heat-treated on-line by passing it through a temperature- and/or atmosphere-controlled chamber prior to ultrasonic consolidation. The feedstock may be supported to minimize slumping due to creep. The feedstock may be T4, or may be aged, to T6, for example. The feedstock may be allowed to age naturally at room temperature, or a heat source may be used to artificially age the consolidated feedstock. The substrate may be aged or unaged. The source of the aluminum-based feedstock is in the form of tapes, sheets, wires, or droplets.

Dependencies are inferred from the claim text.